BCP Precast

GENERAL INSTALLATION REQUIREMENTS

1. Correct installation of BCP Covers and Frames is essential for the installed cover to operate satisfactorily and
give the long service life that it has been designed for.
2. Failure to install correctly may result in movement or rock under load, excessive wear therefore reduced life,
damage or failure under load and poor sealing between cover and frame seatings.
3. All concrete infill covers and frames should be filled with structural grade concrete and allowed to cure with covers
installed in frames.
4. Generally, the side that has either two or four keyholes indicates the side that the cover should be removed
from the frame.
5. An approved sealing compound is recommended for all cover and frame seatings.

 

CAST IRON COVER INSTALLATION PROCEDURE

STEP 1 - FORM A REBATE IN THE PIT OPENING

  • Recommended rebate sizes are shown below

STEP 2 - REMOVE THE COVER FROM THE FRAME

  • Mark or tag the frame end in which the cover lifting end seats.

STEP 3 - LOCATE AND LEVEL THE FRAME IN THE REBATE

  • Ensure that the frame is correctly oriented for the required direction of cover removal.
  • Pack under each corner joint of the frame to raise and level the frame top with the rebate top.
  • Ensure that the packing and frame do not protrude into the pit opening.
  • Units with additional frame joints on undercut and drawcut seating ends: pack underneath and behind
  • joints to prevent bowing of frame.
  • Check for any rocking motion between diagonally opposite frame corners. Adjust packing to eliminate rocking of frame.

STEP 4 - SET UP THE INTERNAL FORMWORK

  • Ensure that the formwork does not project above the horizontal seating surface of the frame (Otherwise the cover cannot be seated prior to concrete infill).

STEP 5 - CLEAN THE COVER AND FRAME SEATINGS

  • All cover and frame seating surfaces must be free of dirt or dust to ensure the correct seating of the cover in the frame.

STEP 6 - PLACE THE COVER IN THE FRAME

  • Ensure that the cover is correctly oriented in the frame according to the mark or tag.
  • Ensure that the keyhole plugs are fitted.
  • Check for any diagonal rocking movement between the cover and the frame and adjust the frame packing
  • if necessary.
  • Run a finger along the top edges of the cover and the frame and check that the edges are level over the whole perimeter of the unit (If not level, dirt may be present in the seating surfaces or the frame may be distorted due to rough handling).

STEP 7 - POUR THE CEMENT INFILL (IF REQUIRED)

  • Pour the concrete and tap down to ensure all cavities in the rebate, the infill cover and frame cells (if required) are completely filled.

STEP 8 - SEAL THE UNIT FOR OPERATION

  • Remove the cover and internal formwork.
  • Clean all cover and frame seating surfaces.
  • Apply sealing compound liberally to all vertical and horizontal seating surfaces of frame.
  • Install the cover in the frame and tamp down the cover at the keyholes until the top edge of the cover is level with the top edge of the frame.
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